Composition for molding and process of making same



for molding and to Patented Feb. 2, 192

imrrsu STATES PATENT OFFICE.

TREVOR S. HUXHAM, OF BLOOMFI ELD, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGN- MENTS, TO CARLETON ELLIS,

OF MONTCLAIR, NEW JERSEY.

COMPOSITION FOR MOLDING AND PROCESS OF MAKING SAME.

No Drawing.

To all whomitmay concern: Be it known that I, Tnnvon vS. HUXHA'M, a citizen of the United Sta s, residing at- Bloomfield, in the county of ssex and State of New Jersey, have invented certain new and useful Improvements in Compositions for Molding and Processes of Making Same, of which the following is a specification.

This invention relates to a composition the process of making same and relates especiall to plastic compositions containing a bin er derived by the reaction between an aldehyde and a phenol. In molding plastic substances such as those made from the resinous condensation products of phenol and formaldehyde difficulty arises from time to'tinfe due to stick ing of the material to the mold. The cause of sticking has not been definitely established and not infrequently causes trouble in molding establishments; However byg'rea'sing the molds or by adding a small amount,

of stearic acid to the molding composition a degree of lubrication 1s obtained which overcomes sticklng in some cases. The requirements of present day molding frequently call for a plastic material which will set or become thermo-rigid when hot pressed and may be taken from the mold in a cured condition just as rubber is'vulcanized. If

the article sticks to the mold delayarises xand the mold afterward, has to be repolished. It is possible to minimize sticking difliculties by chilling the article While.

still in the mold by placing in a, cold press but this second operation consumes time and is not desired. Therefore a molding composition to be satisfactory should not give at the most more than very slight sticking difliculties.

Resins may bev prepared by reacting with furfural on phenol and these resins may be admixed with fillers in the manner customary With the phenol formaldehyde products referred to above using-for example any of the customary filling agents ordinarily employed in the plastic art. Wood flour being an example. The resinous material incorporated with filler to make a molding composition; even though it has the property- I of setting satisfactorily in themold on heat- Application filed October 2, 1922. Serial No. 591,942

inordinate depeculiarity of If this sticking were only slight,

employe mold lubricants, with their disadw vantages of rendering the surface of the molded article acid in the mo ding composition sticking difficulties are constantly in evidence. 4

In the manufacture of matrices or printing plates molding with furfural resin is possible because a sheet of tin foil'is interposed between the mold and the molding composition and this prevents sticking. For the usual run of molded articles howeverno such'means are at hand to prevent sticking and in the present invention a composition will be described which although containing or consisting of furfural resin to themold at least in any degree such as to preclude it from being used for commercial molding urposes.

The essential eature of the present invention is the incorporation in the molding composition containing resins which exhibit the sticking properties, for example the furfu'ral resin of a small quantity of ametallic soap such as zinc stearate or aluminum palmitate and the like. i

The term metallic soapl has heretoforebeenused in? the literature, as referring to easy, or by using steal-1c does not stick the fatty acid or resin acid salts of the metals other salts being ample page 266 than the alkali metals, such insoluble in water (see for ex-' of Ellis, SyntheticResins' and'lheir Plastics N.- Y. 1923). The said term is employed in that sense in the present case, and is not intended to include water-soluble soaps such as ordinary soda or potash soaps. I

Thus a resin may pounds of phenol, 7 pounds of furfural and 1 pound of potassium carbonate under a refluir condenser. for 3 hoiirs at 145155 C Any excess of phenol is then removed be made by heating 1Q blowing with'steam. The solid fusible'resin obtained is used as the basis of a molding composition. For example as follows:

' 75 parts by weight of the resin are dissolved in an eq'uahweight of denatured 1,571,447 x x a tallic soap, the latter being presentin an ing to the mold in-hot moldin operations, amount not exceeding a few per cent of the and a small amount of metal ic soap, the entire quantity of the composition. latter being present in an amount not ex--'1o 11. A molding composition comprising an cee'ding a. few per cent of the entire quantity] 5 admixture of a resinous binder which has of the composition.

the property of hardening when heeted and 1 which normally exhibits a tendency to stick TREVOR S. HUXHAM. 

